Binary precast concrete triangulated building system

ABSTRACT

The invention relates to a prefabricated building structure utilizing precast concrete steel reinforced T-shaped building elements and precast concrete steel reinforced hexagonal shaped columns. The T-shaped building elements are arranged in building units to form the framework of the building structure, said units respectively constituting the floors and roof of the structure and being vertically aligned and spaced apart by means of the columns. Each building element comprises a diamond shaped slab and an integral beam extending along the major axis of the slab on the under side thereof. The hexagonal shaped columns are each provided with a plurality of vertically spaced annular shelves upon which the ends of the T-shaped building elements on the major axes thereof rest. Moment connections are welded in the field between adjacent slabs and between the building elements and columns.

United States Patent 1 [1 3,733,762 Pardo 1 May 22, 1973 541 BINARYPRECAST CONCRETE TRIANGULATED BUILDING SYSTEM [76] Inventor: JorgePar-d0, 20181 Exeter, Detroit,

Mich. 48203 [22] Filed: May 18, 1971 [21] Appl. No.: 144,547

[52] US. Cl. ..52/263, 52/237, 52/319, 52/61 1 [51] Int. Cl. ..E04b5/04, E04b 5/23 [58] Field of Search ..52/263, 236, 234,

[56] References Cited UNITED STATES PATENTS 1,046,582 12/1912 Gilbreth..52/611 1,301,561 4/1919 Hirschthal ..52/283 X 2,000,110 5/1935 Venzie..52/601 X 2,569,669 10/1951 Henderson. .....52/283 2,959,256 11/1960Deam .52/263 X 3,239,913 3/1966 Richmond ..52/587 X 3,372,518 3/1968Rensch ..52/263 X 3,500,601 3/1970 Hamill ..52/236 3,527,002 9/1970 Mead..52/237 X 3,600,863 8/1971 Nachfsheim ..52/236 X Primary Examiner-PriceC. Faw, Jr. Attorney-Whittemore, Hulbert & Belknap [57] ABSTRACT Theinvention relates to a prefabricated building structure utilizingprecast concrete steel reinforced T- shaped building elements andprecast concrete steel reinforced hexagonal shaped columns. The T-shapedbuilding elements are arranged in building units to form the frameworkof the building structure, said units respectively constituting thefloors and roof of the structure and being vertically aligned and spacedapart by means of the columns. Each building element comprises a diamondshaped slab and an integral beam extending along the major axis of theslab on the under side thereof. The hexagonal shaped columns are eachprovided with a plurality of vertically spaced annular shelves uponwhich the ends of the T-shaped building elements on the major axesthereof rest. Moment connections are welded in the field betweenadjacent slabs and between the building elements and columns.

11 Claims, 12 Drawing Figures PATENnm m 3.783.762

SHEET 1 OF 3 J3 50 INVENTOR uaea; PABDO BY A? A ORNEYS BINARY PRECASTCONCRETE TRIANGULATED BUILDING SYSTEM BACKGROUND OF THE INVENTION 1.Field of the Invention.

The construction industry is in the midst of a process of re-evaluationand re-discovery and can be described or defined as being a collectionof trades bypassed by the so-called industrial revolution at thebeginning of the century. The construction industry only recentlyadopted or attempted to adopt the mass production techniques alreadyfamiliar in the manufacture of many consumer-oriented products. Theprincipal factor for the delayed industrialization of a heretoforemedievalin-approach building situation has been the population increaseand the inability of conventional construction to provide housing atsuch an unprecedented rate. In Europe, the crisis arrived earlier thanin the United States, as a result of the large devastation caused by twoworld wars; and as a result, volume production and standardization havebeen developed to a far greater degree than in the United States.

In the construction industry, two different structural systems are inuse: (a) post & beam; and (b)-bearing panels. Each of these systems hasinnumerable variations according to degree of fabrication, materialsused and country of origin. All variations, in turn are based onrectangular modules, which is another way of expressing the fact thatall their angles are 90. Post & beam systems, whether steel or concrete,necessitate floor (roof) diaphragms for their realization Panel systemsinclude floor elements, but their deck-of-cards" assembly makes themprone to failures such as the Ronan Point disaster in England; whilelimiting their vertical scope.

It is the general practice in the construction industry that the floorand ceiling of a building structure be constructed of building elementsin the shape of flat, rectangular bodies which have been prefabricatedby moulding and which are joined together in situ to form said floor andceiling. The conventional shape of the building element limits the scopeof design of the structure and frequently makes it impossible to adaptthe structure to the landscape or other environment, with the resultthat aesthetic considerations must be foregone. Furthermore, thehandling on the building site of the conventional building elementrequires a large labor force, use of large mechanical liftingappliances, scaffolding, and wooden framework.

The present invention reduces the labor force required to handle thebuilding elements for erection of building structures; eliminates theintrinsic disadvantages of prior art systems; and provides a greaterflexibility of design of such structures than has been achievedheretofore with conventional building ele ments, particularly withregard to subsequent vertical extension causing minimum inconvenience tothe occupants of the building, and the provision of a wide variety ofshapes for the building structure.

2. Description of the Prior Art.

The Hamill U.S. Pat. No. 3,500,601 of March 17, 1970, the Camoletti etal U.S. Pat. No. 3,363,370 of Jan. 16, 1968, the Deam U.S. Pat. No.2,959,256 of Nov. 8, 1960, and the Deam U.S. Pat. No. 2,922,299 of Jan.26, 1960 each discloses a prefabricated building structure as does thepresent invention; however the building structure disclosed herein isstructurally dissimilar from the prior art building structures in thegeometrical shape of the T-shaped building elements and. columnsemployed and in the manner in which the components are assembled. TheI-Iirschthal U.S. Pat. No. 1,301,561 of Apr. 22, 1919, the Moore U.S.Pat.

No. 1,376,152 of Apr. 26, l92l, the Winston U.S. Pat

No. 1,745,880 of Feb. 4, 1930, the Henderson U.S. Pat. No. 2,569,669 ofOct. 2, 1951 and the Richmond U.S. Pat. No. 3,239,913 of Mar. 15, 1966each relate generally to component parts of building structures throughbeing structurally dissimilar from the present invention.

SUMMARY OF THE INVENTION minor axis of the slab.

The prefabricated T-shaped building elements are provided during themanufacture thereof with insert plates at the four corners thereof andwith at least one insert plate along the edge of each side of the slabintermediate the corners. The insert plates are provided with anchoringrods which are embedded in the slab during fabrication. Momentconnectors or elements are welded to the insert plates in the fieldbetween adjacent slabs and between the T-shaped building elements andcolumns to provide a strong framework capable of withstanding theconditions of load.

Each precast concrete steel hexagonal shaped column is provided with aplurality of vertically spaced annular shelves. Each shelf includes arim portion extending laterally from the column and upon which an end ofa T-shaped beam rests. Each shelf is adapted to support the ends of sixadjacent T-shaped building units. Each column is further provided with aplurality of annular bands corresponding in number to the number ofshelves. Each band consists of an insert plate embedded in each side ofthe six sided column during the fabrication of the column. Momentconnecting plates are welded to the column insert plates in the fieldduring the erection of the framework of the building structure.

A purpose of the present invention is to standardize the T-shapedbuilding elements and hexagonal shaped columns thus permitting suchunits to be mass produced so as to reduce costs, obtain a superiorstructure at a permissible cost and to further obtain uniformity ofconstruction.

A further purpose of the present invention is to provide a prefabricatedbuilding structure wherein a plurality of the T-shaped building elementsare arranged in a unit to form a floor, ceiling or roof and a pluralityof such units are vertically aligned and spaced apart by means of theprecast concrete reinforced columns.

Another purpose is to provide a structural framing system of suchconfiguration that it contains inherent fabrication, erection, cost andengineering advantages over conventional systems of comparable range andperformance.

The binary triangulated system of the present invention is an opensystem in the sense that it can accommodate elements from other systemsfor its walls and finish; while avoiding the excessive weight and areaof bearing walls. The geometry of the system-is such that floor layoutand facade variations equal in. number snowflake configurations.Dimensions of system members are calibrated to make full utilization ofexisting building material and to accommodate virtually any type ofavailable curtain wall. Construction of the T- shaped building elementsand columns allows rapid setup construction by local precasters withoutrequiring the expensive, elaborate equipment and locale required bypaneled systems.

IN THE DRAWINGS FIG. I is a fragmentary plan view of a typical floor orroof of the framework of the building structure;

FIG. 2 is a fragmentary elevational view of the frame work of thebuildingstructure;

FIG. 3 is a perspective view of the precast T-shaped building element;

FIG. 4 is a perspective view of the precast hexagonal shaped column.

FIG. 5 is a sectional view, with parts broken away, through a T-shapedbuilding element taken on the line 5-5 of FIG. 1.

FIG. 6 is an enlarged view of part of FIG. 1, illustrating a typicalmoment connection between a pair of adjacent slabs;

FIG. 7 is a sectional view of a typical moment connection taken on theline 7-7 of FIG. 6;

FIG. 8 is an enlarged view of part of FIG. 1, illustrating a typicalmoment connection between the 120 corners of three adjacent slabs;

FIG. 9 is a sectional view taken on the line 99 of FIG. 8;

FIG. 10 is an enlarged sectional view through a column taken on the linel0-l0 of FIG. 12 and showing the six moment connector plates between theslabs and column;

FIG. 11 is a sectional view through a column taken on the line 11--l1 ofFIG. 12 and showing the bottom view of the T-shaped building elementsand the utility voids therein; and

FIG. 12 is a vertical sectional view through the column and buildingelements, taken on the line l2--l2 of FIG. 10.

Referring now to the drawings, FIGS. 1 and 2 illustrate the framework ofa building structure 10 which uses a plurality of identical precastconcrete steel reinforced T-shaped building elements 12 and a pluralityof identical precast concrete steel reinforced hexagonal shaped columns15. The T-shaped building elements 12 are arranged in side by siderelationship, as shown in FIG. 1, to form a plurality of building units16 for each floor and roof of a one or multistory building structure.The T-shaped building elements or units 12 are joined together to formthe floors, ceilings and roof of the building structure. The buildingunits 16 for each floor 18 are aligned vertically and spaced apart, asshown in FIG. 2, and together with the structural supporting columns l4aforesaid provide the framework for the building structure 10.

FIG. 3 illustrates a typical T-shaped building element 12 whichcomprises a diamond shaped slab 18 having a major axis 20 and a minoraxis 22 and an integral concrete beam 24 extending along the major axis20 of the slab 18 on the under side thereof. The four sides 26, 28,

30 and 32 of the diamond shaped slab 18 are equal in length, with thesides being so arranged as to provide two corners of each, arranged onthe minor axis 22 of the slab 18, and two corners of 60 each, arrangedon the major axis 20 of the slab 18. The intersections of the sides 28,30 and 26, 32 of the slab 18 defining the 120 corners are sharp orpointed, while the intersections of the sides 30, 32 and 26, 28 definingthe 60 corners are formed flat as best illustrated in FIG. 3 to provideend surfaces 34, 36 each having a width approximately equal to the widthof the beam 24. The slab 18 has a flat generallysmooth upper surface 38and a flat generally smooth lower surface 40.

The concrete building element 12 is prefabricated in the factory. Thepressure-vacuum extraction method of casting may be employed as analternative to the conventional type of metal framework usuallyemployed. As best illustrated in FIG. 5, the slab l8 and beam 24 of theTl-shaped building element 12 are reinforced with steel rods 42 and 44respectively. The concrete slab 18 may also be reinforced with steelmesh, glass fiber or matting, or synthetic fibers or matting, as isconventional in the art. The beam 24 of the T-shaped building element 12may be manufactured from conventional reinforced concrete, asillustrated in FIG. 5 by rods 44 or the beam 24 may be made by methodsutilizing prestressed concrete or post tension concrete as is well knownin the art.

During the manufacture of the T-shaped building element 12 steel insertplates 46 are embedded in the upper surface of the concrete slab 18 atthe 60 corners as shown in FIG. 3 with the upper surface of plates 46flush with the upper slab surface 38. Steel insert plates 48 areembedded in the upper surface of the slab at the 120 corners as shown inFIG. 3 with the upper surfaces of plates 48 recessed inwardly fromsurface 38. Each of the sides or edges of slab 18 is provided with asteel insert plate 47 intermediate the corners. The top surfaces ofplates 47 are recessed inwardly from surface 38 of the slab 18. Thelower surfaces of the beam 24 which rest on the annular shelf of thecolumn 14, to be subsequently described, are provided with metal insertplates 49 and 51 (FIG. 12). The outer surfaces of insert plates 49 and51 are flush with the bottom surface of beam 24. All of the metal insertplates 46, 47, 48, 49 and 51 embedded in the T-shaped element during themanufacture thereof are each provided with one or more anchors orreinforcing rods 53 as shown in FIGS. 7, 9 and 12 to secure the insertplates to the building element 12.

The side edges of the slab 18 are provided with an elongated groove orgrout key 50 which is used for a purpose to be subsequently described.It will be noted when referring to FIG. 5 that the width of the lowerrib or flange of the groove 50 is greater than the width of the upperrib or flange.

Each T-shaped building element 12 is provided with a utility void or acast-in aperture 52 (FIGS. 3, 5 and 11) which extends substantially theentire length of the beam 24 and has right angled ends thereof openingthrough the side walls of the beam 24 as best illustrated in FIGS. 3 and11. Electrical or other utility type conduits or elements, not shown,may be inserted into the voids 52 of the T-shaped building elements 12after the erection of the building structure 10. Thus, the T- shapedbuilding element 12 is designed to provide a comprehensive conglomeratesystem which includes structural, architectural, electrical andmechanical functions.

The building structure further includes standardized precast verticalsupport members or columns 14 each in the form of a hexagonal shapedprecast concrete steel reinforced elongated member. The column 14 may bemanufactured by utilizing conventional types of metal formwork or byother commercially known methods of casting. The concrete column 14includes a plurality of reinforcing rods 54. In addition, the column 14includes one or more annular shelves 56 of hexagonal configurationcorresponding in number to the number of floors in the buildingstructure 10. The shelf 56 consists of a vertically extending annularportion 58 which is embedded in the concrete, as illustrated in FIG. 12,and of a laterally extending annular rim portion 60, perpendicular tothe vertical portion 58, which extends laterally from the column 14 asbest illustrated in FIG. 12. The ends of the T-shaped building elements12 on the major axes thereof, which are provided with the metal insertplates 49 and 51, rest upon the shelves 56 as shown in FIG. 12.

Spaced vertically upward from each annular shelf 56 is an annular band62 of metal inserts or plates 64, one insert 64 for each side 66 of thehexagonal shaped column 14 as shown in FIG. 4. Each insert plate 64 isprovided with one or more anchors or reinforcing rods 65, as showninFIG. 12, to secure the insert plates 64 to the column 14. The outersurfaces of the metal inserts 64 are flush with the outer surface of thecolumn 14as best illustrated in FIG. 12. Thus each shelf 56 has acorresponding metal band 62. The lower end of the column 14 during themanufacture thereof is provided with an internally threaded insert 68which is adapted to be connected to an anchor bolt 70 provided in thesite poured concrete footings 72 of the foundation 74 of the buildingstructure 10 as best illustrated in FIG. 2. i

In erecting the building structure 10, the anchor bolts 70 and otherstructural steel members, not shown, are placed in the foundation. Thebolts 70 are located at a predetermined column spacing, there being oneanchor bolt 70 for each column 14. The concrete foundation 74 andfootings 72 are poured in a conventional manner well known in the art.After the concrete has set the vertically extending precast columns 14are appropriately secured to the anchor bolts 70 as shown in FIG. 2. Asan example, the columns 14 are arranged in horizontally and verticallyextending rows as shown in the plan view in FIG. 1. With such aconstruction it should be noted that three adjacent columns are locatedat the apexes of a triangle. The first floor 73 is then superimposedover the foundation 74. The first floor 73 may be concrete or made fromprefabricated building elements.

Once the vertically extending columns 14 have been erected andappropriately anchored, the second floor of the building structure 10 isinstalled, with each T- shaped building element 12 having the ends ofthe beam 24 supported on the annular shelves 56 of adjacent columns 14.Once the plurality of T-shaped building elements 12 have beenappropriately installed on the columns 14 to form the second floor ofthe building structure 10, it is necessary to field weld the slabs 18and columns 14 together to form moment connections. Thereafter, it isnecessary to place or insert concrete grouting in the grout key 50formed by the side edges of adjacent slabs '18. i

A moment connector'plate 82 is placed over opposing insert plates 47 ofadjacent slabs 18 and then is field welded on the ends thereof to theinsert plates 47 as illustrated in FIGS. 6 and 7. As illustrated in FIG.1 the inner T-shaped building elements 12 will have four momentconnector plates 82 securing one slab' 18 to the four adjacent slabs 18.

A hexagonal shaped moment connector plate 84, illustrated in FIGS. 8 and9, is placed over opposing insert plates 48 of three adjacent slabs 18and is then field welded on the edges thereof the insert plates 48. FIG.1 illustrates typical moment connector 84 on the minor axes 22 of slabsl8.

' In addition, moment connections are also provided at each column 14 asillustrated in FIGS. 10 and 12. The annular shelf 56 is welded at 86throughout the periphery thereof to the insert plates 49 and 51 providedon the bottom side of the beams 24 of the T-shaped building elements 12.In addition, angle shaped moment connectors 90 are provided each havinga vertical web 92 and a horizontal web 94. One moment connector 90 isprovided for each end of the slab on the major axis 20. The horizontalweb 94 is welded to the metal insert 46 provided in the slab 18 whilethe vertical flange or web 92 is welded to the corresponding "metalinsert plate 46 located in the column 14. As shown in FIG. 10, thecolumn 14 supports the ends of six T-shaped building elements 12 and sixangle shaped moment connectors 90 tie the elements 12 to the column 14.;

After the second floor of the building structure 10 is constructed inthe manner described heretofore the process is continued up to thehighest part of the building structure 10 where the last floorsimultaneously forms the roof part of the structure.

The construction of the walls and facing of the building structure 10may be effected in any conventional manner, and the invention is notconcerned with this aspect of the building structure. In addition to theunlimited possibilities of extending the construction horizontally inall directions, the prefabricated building elements l2 and columns 14according to the invention allow a similar development in height. TheT-shaped building elements provide for added flexibility of plan shapelayout in the overall building structure.

If it is necessary at a later date to dissemble the structure 10, thefloors and roof can simply be removed after first removing the variousconnector plates aforesaid and the grout keys 80. Thereafter the slabunits 12 can be lifted by a crane and treated as interchangeable unitsto be employed in a new building.

Once the building elements 12 have been installed and the plurality ofmoment connections field welded in place to complete the floor, a cementfield topping is placed on the slabs 18 to cover same including thevarious connector plates as shown in FIGS. 2, 7 and 9.

Once the floors and roof of the building structure 10 have beencompleted, the walls and facing are inatalled. The air and electricalconduits may then be installed in the beams 24 via the utility voids 52.Thereafter asbestos cement may be applied between the webs or sides ofthe beams 24 as shown in FIG. 11 to form a typical utility connectingclosure 102.

It will further be evident that the columns 14 and building elements 12will desirably be produced under mass production conditions, and merelyshipped to the location of use. However, if the job is large enough towarrant it, the columns 14 and building elements 12 can be produced onthe job.

What I claim as my invention is:

1. A building structure comprising a plurality of building units whichare vertically aligned and spaced apart by means of vertical columns,each building unit comprising at least three substantially identical T-shaped building elements, each element having a diamond shaped slabprovided with a smooth upper surface and a lower surface and an integralbeam engaging and arranged perpendicular to the lower surface of theslab, each slab having four sides of equal length arranged to form twooppositely facing angles of 60 on a major axis of the slab and twooppositely facing angles of 120 on the minor axis of the slab, theintegral beam of each T-shaped building element extending along themajor axis thereof, said T shaped building elements being joinedtogether, with each slab having one of its sides opposite and in closeproximity to a side of one of the remaining slabs and each slab having asecond side which intersects said one side opposite and in closeproximity to a side of another of the remaining slabs, said verticalcolumns engaging the ends of the T- shaped building elements along themajor axes thereof of each of said building units.

2. The building structure of claim 1 wherein said columns are ofhexagonal cross section. V

3. The building structure of claim 1 wherein said columns are precastand are of concrete reinforced with steel reinforcing elements.

4. The building structure of claim 3 wherein vertically spaced annularshelves are precast with each column, the ends of each building elementon the major axis thereof being supported by the shelves on saidcolumns.

5. The building structure of claim 4 wherein each of said annularshelves is provided with anchoring rod means embedded in thecorresponding concrete column.

6. The building structure of claim 1 wherein the 60 corners of each ofsaid slabs are provided with insert plates embedded in the upper surfaceof the slab, and a moment connector plate spanning the insert plates ofadjacent slabs and being welded thereto.

7. The building structure of claim 1 wherein at least one insert plateis embedded in the upper surface of the slab along the edge of each sidethereof intermediate said corners, and moment connector plates spanningthe sides of adjacent slabs and being welded to the corresponding insertplates.

8. The building structure of claim 7 wherein the four corners of each ofsaid slabs are provided with insert plates embedded in the upper surfaceof the slab, first moment connector means spanning the insert plates onthe minor axes of adjacent slabs and being welded thereto, and secondmoment connector means welded between the insert plates on the majoraxes of adjacent slabs and steel elements embedded in said columns.

9. The building structure of claim 8 wherein vertically spaced annularshelves are precast with each column, the ends of each building elementon the major axis thereof being supported by the shelves on saidcolumns.

10. The building structure of claim 9 wherein all of said insert platesare provided with anchoring rods embedded in the corresponding slab.

11. The building structure of claim 1 wherein the 120 comers of each ofsaid slabs are provided with insert plates embedded in the upper surfaceof the slab, and moment connector plates welded between said insertplates and steel elements embedded in said columns.

1. A building structure comprising a plurality of building units whichare vertically aligned and spaced apart by means of vertical columns,each building unit comprising at least three substantially identicalT-shaped building elements, each element having a diamond shaped slabprovided with a smooth upper surface and a lower surface and an integralbeam engaging and arranged perpendicular to the lower surface of theslab, each slab having four sides of equal length arranged to form twooppositely facing angles of 60* on a major axis of the slab and twooppositely facing angles of 120* on the minor axis of the slab, theintegral beam of each T-shaped building element extending along themajor axis thereof, said T-shaped building elements being joinedtogether, with each slab having one of its sides opposite and in closeproximity to a side of one of the remaining slabs and each slab having asecond side which intersects said one side opposite and in closeproximity to a side of another of the remaining slabs, said verticalcolumns engaging the ends of the T-shaped building elements along themajor axes thereof of each of said building units.
 2. The buildingstructure of claim 1 wherein said columns are of hexagonal crosssection.
 3. The building structure of claim 1 wherein said columns areprecast and are of concrete reinforced with steeL reinforcing elements.4. The building structure of claim 3 wherein vertically spaced annularshelves are precast with each column, the ends of each building elementon the major axis thereof being supported by the shelves on saidcolumns.
 5. The building structure of claim 4 wherein each of saidannular shelves is provided with anchoring rod means embedded in thecorresponding concrete column.
 6. The building structure of claim 1wherein the 60* corners of each of said slabs are provided with insertplates embedded in the upper surface of the slab, and a moment connectorplate spanning the insert plates of adjacent slabs and being weldedthereto.
 7. The building structure of claim 1 wherein at least oneinsert plate is embedded in the upper surface of the slab along the edgeof each side thereof intermediate said corners, and moment connectorplates spanning the sides of adjacent slabs and being welded to thecorresponding insert plates.
 8. The building structure of claim 7wherein the four corners of each of said slabs are provided with insertplates embedded in the upper surface of the slab, first moment connectormeans spanning the insert plates on the minor axes of adjacent slabs andbeing welded thereto, and second moment connector means welded betweenthe insert plates on the major axes of adjacent slabs and steel elementsembedded in said columns.
 9. The building structure of claim 8 whereinvertically spaced annular shelves are precast with each column, the endsof each building element on the major axis thereof being supported bythe shelves on said columns.
 10. The building structure of claim 9wherein all of said insert plates are provided with anchoring rodsembedded in the corresponding slab.
 11. The building structure of claim1 wherein the 120* corners of each of said slabs are provided withinsert plates embedded in the upper surface of the slab, and momentconnector plates welded between said insert plates and steel elementsembedded in said columns.